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The MAGNAL FA.CT.S System is a tool which can help the factory management successfully meet the challenge of achieving overall manufacturing efficiency and effectiveness. The tasks of planning, scheduling and controlling are areas where the MAGNAL FA.CT.S System can assist the factory management in improving their factory's performance and reducing costs.

The area where the MAGNAL FA.CT.S System can help the factory and supervisory management do a better job are:

• Planning to effectively maximize the utilization of the plant's capacity at the lowest possible cost.
• Processing cuts through the factory at optimal efficiency while achieving the shortest possible cost.
• Controlling individual operator efficiencies and performances daily.
  
• Controlling section, factory efficiency and cost.
• Capturing and reporting excess cost by section, and for the factory.
• Capturing the payroll data accurately and efficiently.
• Controlling the work in process.
  

POTENTIAL BENEFITS AND COSTS SAVINGS

Experience has shown that there are real benefits and cost savings from computerizing the piece work payroll and factory controls. The following highlights some of the areas where improvements and costs savings can be made:

• Savings in the Calculation of the Gross Payroll: The manual calculation of the gross payroll normally requires one full-time payroll clerk for each 75 to 100 direct labor operators. The time required to input the coupons and do the gross payroll will be reduced to one third of the time required to do it manually.
  
• Savings in Printing Bundle Tickets: Most factories have a person who spends from 4 to 8 hours per day printing bundle tickets and maintaining the rates by style (either using type cages or typed sheets or stencils). The ticket printing is automated which greatly reduces the work involved in printing bundle tickets.
  
• Improving the accuracy of the data: With the MAGNAL FA.CT.S System there is a check to ensure that the quantity bundled equals the quantity cut, eliminating errors in the bundle quantities and the possibilities of over payments to the operators.
  
• Ability to Change Rates and Quantities per Bundle Quickly and Accurately: With manual ticket system, changes to piece rates and/or bundle quantities is both difficult and time consuming. With the MAGNAL FA.CT.S System, this can easily be done in the computer ensuring correct payment of rates and quantities.
  
• Gaining the Lost time between Clocking In/Out and Starting/Finishing Work at the Work Station: Everyone is familiar with the line ups to clock in/out and the time required to travel to and from the work station. By using the operator's gum sheet as his/her time card, the need for this is eliminated, resulting in a real gain in productivity of 1% to 2%.
  Reduced Work-In-Process: With more timely information available, the floor management can react faster to production problems. Work-in-process inventory levels have always been a function of the delays of getting data and management's ability to react and correct problems. Lower levels of work-in-process are possible by having the production data available when management requires it.
  
• Improved Employee Motivation: An important advantage of computerized data collection is the ability to feed performance data back to the employee on a daily basis. This helps the employees understand how they are performing and encourages them to maintain a good level of performance. For trainees it is an excellent motivation tool whereby they can monitor their performance on a daily basis. Experience has shown that factories do achieve better performances when information is fed back to the employees.
• Improved Planning and Utilization of Factory Capacity: It is very difficult and costly to do detailed planning for most sewn products factories because of the large amount of data which must be calculated and the need for frequent changes to schedules. Automating the calculations permits the factory management to quickly analyze production schedules and to determine where bottlenecks and potential problems exist. In factories, improved planning has resulted in a 4% to 8% reduction in excess costs.
  

AVAILABLE MODULES

• Piecework Payroll and Cost Reporting (Batch or Real Time)
• Modular Payroll and Cost Reporting
• Planning and Work-in-Process Tracking
• Fabric Utilization (including history by cut or style)
• Factory Budget Reporting
• Quarterly Performance Report
• Performance and Attendance Incentive
• Time and Attendance (includes attendance warnings, bonus days)
• Work-in-Process Schedule Exception Reporting
• Trainee Module (including training curves by skill or style)
• Online WIP Tracking
• Computerized Punch Clocks

STANDARD DATA MANAGEMENT

The SDM STANDARD DATA SYSTEM is the latest generation of software which has been developed by people with computer and factory experience to help sewn products companies develop accurate performance standards in a variable style environment.

The SDM System is designed to operate on 486 PC compatibles or higher with software that can easily be learned.

With the SDM system you can purchase Core Data elements specifically designed for sewn products industries. These Core Data elements have been developed based on years of experience using MTM-2. Experience has shown that the Core Data will cover the majority of the elements required for describing cutting, sewing and finishing operations. However, in all factories there will be those special elements which will require custom development to ensure speedy and accurate setting on new production standards. Using MTM-1 or MTM-2, your staff will be able to develop those special custom elements your company requires for bundle handling, special machines etc...

SDM is an open system when it comes to developing Core Data which is applicable to your factory. It allows you to use MTM-1 or MTM-2, or you can enter the predetermined elemental times from another system. Using the predetermined elemental time system you require, you can create core data which is customized to your factory.

The flexibility of the SDM system allows for different Core Data. Depending on your operation, you can use core data which is appropriate for operations which are short, cycle, highly repetitive and are for high volume production or for operations which are low volume production.

FEATURES OF THE SOFTWARE

Methods Development:

• Allowances can be set individually for bundling, handling, machine, manual and special elements.
  
• There is a table of formulas which is very flexible for developing the core data.
  
• You can easily copy elements or incorporate a macro when developing a method.
  
• Standard sets of elements can be developed for a specific factory. These can be quickly incorporated into a new method reducing the time to set standards and ensuring greater consistency.
  
• A flexible memo format for recording notes or additional information specific to that method

Specification Sheet Development


• Groups of operations can be developed according to style features. These can be easily and quickly copied into the specification sheet to develop new styles.
• There are up to 10 different Operation Incentive Rates which can be used to determine the standard dollar cost for the style.
• A flexible memo format for recording notes or additional information specific to that style.
  

Installation and Training:


• On-site training is provided to your company's personnel to ensure that they learn how to develop standards quickly and accurately on you products and for your factory.
  
• Your staff is taught how to develop the special Core Data elements which are unique to your factory.
  
  

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